Cap



A. D. EVERITT April 2l, 1970 CAP 2 Sheets-Sheet 1 lllllllllla Filed July s, 1967 United States Patent O 3,506,979 CAP Allen D. Everitt, 2729 E. Belleview Place,

Milwaukee, Wis. S3211 l Filed July 6, 1967, Ser. No. 651,583

Int. CL A42b 1 06 U.S. Cl. 2-172 12 Claims ABSTRACT OF THE DISCLOSURE A cap construction which permits a single cap to accommodate a wide range of head sizes while retaining its basic shape. The cap body is provided with a concealed reinforcing member which expands with the cap body to accommodate head sizes but also provides support for the cap body so that the cap body retains its basic shape before, during and after such expansion. Furthermore, the main cap body is constructed from a single continuous knit tube, and includes a visor arrangement which permits allowance of sufficient material in the cap body to provide an adequate cuff.

BACKGROUND OF INVENTION Field of invention This invention relates to cap constructions.

Description of the prior art The cap industry has long recognized the need for a cap construction which can be said to have a relatively universal size, i.e. a construction whereby a single cap accommodates a full or 'wide range of head sizes. The most generally accepted approach to solving the problem created by this need has been to include a flexible insert in the cap body which then permits expansion and contraction of the overall cap body dimension to receive and closely t the `wearers head. This approach has not provided a completely satisfactory solution. For example, the main cap body and the insert were generally made of different types of material so that one could provide the necessary rigidity while the other provided the required flexibility, thus additional attention had to be directed to harmonizing the different materials and/ or to concealing the ilexible insert when the cap was in use. Examples of this type of cap construction can be found in U.S. Patents Nos. 2,869,134 and 3,188,654.

SUMMARY OF INVENTION This invention contemplates a cap construction which includes a generally expandable, semi-rigid insert which is associated with the cap body in such a manner that it permits the cap body, which is also preferably fabricated in such a manner as to be expandable, to expand and closely t the wearers head while at the same time retaining its basic configuration.

In its more specific aspects, this invention contemplates that the insert be concealed within the cap body and that the cap body be made from a single, tubular knit member with one end of the tube being closed through the use of` an additional insert which includes a reinforcing member that cooperates in maintaining the basic cap configuration. In those cap designs 'where the cap is to include a movable cuff and where the cap body is formed by a tubular member having inner and outer panels, the cap body is made to extend beyond the lower edge of the main cap body insert so that the insert in the main cap body also functions to define a fold line about which the cufIr can be folded for use. Generally a visor is provided in the cap as well as a-cuif. In order to 3,506,979 Patented Apr. 21, 1970 icc DESCRIPTION OF DRAWINGS FIG. 1 is a front perspective of a cap constructed in accordance with this invention;

FIG. 2 is a rear perspective of the cap of FIG. l with a portion ofthe cap broken away to expose the reinforcing insert;

FIG. 3 is an exploded perspective view of the cap;

FIG. 4 is a vertical section View taken through the cap of FIG. 2;

FIG. 5 is an enlarged lview of a portion of the reinforcing insert;

FIG. 6 is an exploded perspective of an alternative embodiment;

FIG. 7 is an enlarged section view taken through the cap of FIG. 6;

FIG. 8 is a view of the tubular knit body in the initial stage of fabrication; and

FIG. 9 is a rear View of the cap of FIGS. 6 and 7 with parts removed to expose the reinforcing insert.

DESCRIPTION OF PREFERRED EMBODIMENT The cap illustrated in FIGS. 1-5 of the drawings as embodying this invention includes a crown 10, depending side portion or cap body 12, visor 14 extending from the front of the cap and a cuff 15. As is perhaps best illustrated in FIG. 4, cap body 12 is made of a single tubular member folded back on itself intermediate its axial ends to provide a double thickness. End 16 of the cap body is closed by closure panel 18 to form the cap crown and end 20 remains open to afford a conventional cap construction. The construction of closure panel 18 and its attachment to the side portion will be explained more completely hereinafter. y

The side portion or body of the cap is such that it is expandable in a circumferential direction or, in other words, in a direction generally parallel to the plane of open end 20, i.e. the plane including the edges of side portion 12 forming the open end with cuff 15 turned up. For reasons which will become more apparent hereinafter, the cap body is preferably formed by knitting a continuous tube with a section of the tube being taken and folded back on itself as illustrated in FIG. 4. A knit body is favored as this inherently provides the capabilities of expansion and contraction but other expandable and contractable materials may be used. Knit caps, caps of rigid material with and without flexible inserts sewn into the cap to permit expansion and similarly constructed caps have been known in the past; however, such prior caps possessed limited ability to expand to t a wearers head and as a result had to be made in a variety of sizes to accommodate the wide range of prevalent head sizes. In the cap of this invention, a reinforcing insert 22 s positioned between the folds 24 and 26 of the cap side portion. Preferably, insert 22 is a piece of conventional buckram. Buckram is well known in the garment and millinery industry and in one of its more popular forms consists of strands of cotton or the like which are arranged generally at right angles to each other and heavily sized so that they afford a relatively stiff finished element. A portion of the buckram has been enlarged and illustrated in FIG. 5. The buckram element is cut on a bias and in a continuous generally elongated or rectangular strip. By bias is meant that although the strip includes opposite parallel ends 28 and 30 and longitudinal edges 32 and 34, the element is cut so that its basic ibers 22a and 22b are arranged at an oblique angle to the opposite ends and edges of the strip or, in the cap, at an oblique angle to the circumferential line of the cap body. The buckram will resist a pull parallel to either of its basic fibers 22a and 22b but will expand in response to a force at an angle to the fibers. Also when the pull is released the buckram will tend to contract and return to its normal position. The buckram provides vertical support for the cap body and in that sense is a somewhat rigid insert and yet is also somewhat resilient in the sense that it expands and contracts in a circumferential direction. In this manner when the insert is arranged within the cap body as illustrated in FIG. 4 it is capable of expanding and contracting with the cap body along a circumferential line or generally parallel to the plane of the open end of the cap. Moreover, it is sufficiently rigid to afford support for the body so that the cap maintains its basic shape before, during and after expansion to a given head size.

In order to provide optimum reinforcing, the strip extends completely around the circumference of the cap body with its opposite ends 28 and 30 meeting at the rear portion of the cap as illustrated in FIGS. 2 and 3. Preferably, ends 28 and 30 of the insert are connected at the rear of the cap by a tack stitch 36. The tack stitch is made adjacent upper edge 32 and passes only through the buckram insert and not through either fold 24 or 26. In this manner, the positioning of the buckram insert is maintained as is the freedom of movement between the cap body and the -buckram insert.

This combination of expandable body and expandable insert permits wide latitude in the expanded size of opening 20 of the cap while maintaining a basic overall cap configuration. Moreover, the cap being knit and the buckram insert being cut on a bias, as discussed above, insures that the cap will also contract to fit snugly on the Wearers head. Optimum accommodation to various head sizes is further achieved by leaving the lower edges of the insert free for relative movement. With this cap construction a single cap will accommodate a wide range of head sizes thereby reducing inventory problems usually encountered in connection. with caps. In other words, only a single basic cap size, or a minimum number of general cap sizes need be stocked and will accommodate all head sizes.

It will also be appreciated that configurations other than that specifically disclosed in the drawings can be utilized with the basic concept of this invention.

Although visor 14 is illustrated, the visor can be eliminated if desired. Where the visor is utilized, a reinforcing insert or backing board 40A is used to define the visor. In a conventional manner, this insert may be placed between folds 24 and 26 in the cap body and a holding stitch 42 is then made at the juncture between cap body 12 and visor 14 to hold the visor shape and prevent movement of reinforcing member 40.

Before specifically describing closure panel 18, it should be noted that end 16 of the cap can be closed in any suitable manner. As illustrated, the closure is made utilizing panels 44 and 46 which are of the same fabric as cap body 12. More particularly where body 12 is knit, panels 44 and 46 are also knit. Preferably, a second reinforcing element 48 is sandwiched between panels 44 and 46 and insert 48 consists of a generally annular piece of buckram which extends continuously around the crcumferential edges of panels 44 and 46. Again buckram insert 48 is cut on a bias and arranged with its basic fiber elements extending at an angle to both the radial and circumferential line of the insert to afford a degree of mobility as well as rigidity to the cap crown. Panel 18 is placed in engagement with the edges of folds 24 and 26 and the peripheral edges of panels 44 and 46 and insert 48 are connected to those edges by a stitch 50, the stitch passing through the edges of folds 22 and 24, panels 44 and 46, and insert 48. Insert 48 assists insert 22 in maintaining the basic cap configuration.

Vconstruction which has been described to this point is particularly well adapted to insuring proper manipulation of the cuff as well as to actual formation of the cuff. More particularly and with reference to FIGS. 3 and 4, where cuff 15 is to be provided cap body 12 is made'to have an extension beyond the lower edge 34 of buckram insert 22. Where both a cuff and visor are provided this is readily accomplished by making the knit tube of sufiicient length to have an extension of material depending below the lower longitudinal edge 34 of insert 22, this extension then being used both to provide the cuff and to encircle the insert 40. It will also be noted that by extending insert 22 completely around the cap body the visor, when stitched in place, locates insert 22 with respect to the cap body and will maintain that location without any externally visible stitching which would interrupt the uniform outer appearance of the cap. The insert terminates above the cuff and the lower edge 34 of buckram insert 22 also defines a fold line about which the cuff can be folded to assume either one of its two positions and without interference .with or disturbance of the side portion of the cap since the edge 34 provides a permanent concealed fold line.

FIGS. 6-9 illustrate a refinement of the cap construction of FIGS. l-5 and the steps in fabricating that cap. The discussion of this embodiment will be additionally illustrative of the manner in which the use of a single knit tube facilitates manufacture of the cap.

Similar to the embodiment of FIGS. 1-5, the cap body is formed of a single knit tube 50 turned back on itself to afford a double thickness. The buckram insert is positioned between inner and outer folds 52 and 54. The upper end of the cap body is closed by closure panel 56, the construction of this panel and its connection to the side portion of the cap body is identical to that discussed in connection with the embodiment of FIGS. 1-5 and for that reason will not be described in detail at this point.

This embodiment also illustrtaes an alternative buckram arrangement for the cap body. In contrast to the previous embodiment wherein a single layer of buckram was used, this embodiment utilizes a double layer of buckram. Two separate buckram panels 58 and 60 are overlaid one on the other and rolled into a tubular or cylindrical shape conforming to the shape of the cap body. The buckram inserts each include opposite edges 62-64 and 66-68 and opposite ends 70-72 and 74-76. Preferably, the inserts are overlaid one on the other so that ends 70, 74 and 72, 76 are in juxtaposed relationship. The inserts are then rolled so that the sets of juxtaposed ends overlap and a connection is made between the overlapped inserts by a stitch 78 to hold the tubular configuration. The stitch is made adjacent juxtaposed ends 70, 74 but is spaced inwardly from ends 72, 76. Ends 72, 76 are cut adjacent edges 62 and 66 to form bevels 80 and 82. The inserts are again cut on a bias and arranged with their basic fibers at an oblique angle to the circumferential line of the cap body. With this construction the buckram inserts permit the cap body to expand as a result of both the inherent characteristics of the biased buckram inserts and the freedom of movement between the connected ends of the inserts adjacent edges 62 and 66. With stitch 78 positioned as described, the stitch provides a pivot about which ends 72 and 76 move while ends 70 and 74 remain substantially stationary. FIG. 9 shows only ends 72, 76 as having been displaced as the open end of the cap is expanded as shown. Beveled corners 80 and 82 prevent moving ends 72 and 76 of the buckram inserts from extending beyond edges 62 and 66 and catching on the cap body, which is particularly significant when cuff 88 is turned up.

This embodiment also illustrates a particular visor construction which permits allowance in the cap body of suicient material for an adequate cuil" without creating excess material in the visor area which could detract from the overall appearance of the cap. structurally, cap body 50 is provided with a visor portion 0r extension 84 which is folded over visor backing board 86 with the outer edge of the visor extension being connected into the cap body. Thus, a substantial extension of cap body 50 beyond buckram inserts 58 and 60 is possible to provide an adequate cuif 88 with the excess material being taken up in the visor construction just described. For a better understanding of the cap construction, the steps of manufacturing the hat will be described, this description will also emphasize the advantages gained from using a continuous tubular knit stock in the cap.

A tube is knit in a conventional manner and is then turned back on itself to form the inner and outer panels 52 and 54. Two generally axial cuts 90 and 92 are taken in the folded end 94 of the tube, the cuts being taken at relatively spaced points on the periphery of the folded end. The knit tube is then sheared in the area of cuts 90 and 92 to form relatively spaced inwardly projecting notches 96 and 98 defining visor portion 84 therebetween. In the shearing operation, the knit stock is cut along the outline shown in FIG. 6 to form the just described notches and simultaneously an elastic type band 100 is sewn over the cut edges. The elastic band is tightly sewn over the major extent of visor portion 84 so that it has a tendency to gather the. knit material along the edge of the visor portion and in the notches. As will appear from the following discussion, during the shearing step the operator can control the amount of gather in the knit material by manipulation of the elastic strip as it is sewn into the cap body. For example, the edge of portion v 84 will be stretched in making the connection into the cap body so that a greater amount of initial gather in that area is desirable to afford an appearance uniform with the remainder of the cap when subsequently stretched. In contrast, the part of the edge adjacent the cuff will not be stretched and hence less gather may be required. This variation can be achieved by the operator.

After the shearing step, visor backing portion 86 is laid onto Visor portion 84 between notches 96 and 98 and the visor portion is folded over the board with its outer edge, that covered by tape 100, extending over the inner edge 102 of the backing board and being connected into the cap body by stitch 104. The stitching forms the juncture between the visor and the cap body and, in a manner similar to that discussed in connection with the previous embodiment, it is positioned adjacent the lower edges 62 and 66 of the buckram inserts so as to hold the buckram inserts in the desired area between panels 52 and 54. As stated the shearing operation and the application of the elastic band 100 is significant in that, since the material was gathered along the outer edge of the visor portion, the knit material when sewn into the cap body by stitch 104 remains taut about the board and in the juncture thereby maintaining a neat trim outer appearance for the cap. It will also be noted that this construction takes up excess material and maintains a uniform appearance over the visor which is consistent with the remainder of the cap.

As illustrated notches 96 and 98 are preferably generally arcuate with one side of the arc being lost in the visor construction whereas the other side now forms the front edge of cuff 88.

Closure panel 56 can be sewn into the upper end of the cap body at this point or could havebeen sewn in previously, for example, prior to assembly of the visor.

With the reinforcing insert of this invention the material or fabric for the cap body can be selected virtually without regard to its ability to maintain the basic shape of the cap body. The material can be relatively exible or expandable, while still being somewhat rigid to hold a basic shape, to thereby contribute to the universal nature of the cap from the standpoint of size. This construction also affords a wider selection of material from an aesthetic standpoint and,l it will be noted that with the particular disclosed construction, the various structural elements of the cap are maintained in the desired position with a minimum of external stitching, which might otherwise interrupt the external appearance of the cap. This construction also affords a wide selection in cap designs from a structural as well as an aesthetic standpoint.

Although this invention has been illustrated and described in connection with particular embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention.

I claim:

1. A cap comprising, in combination,

a cap body comprising an elongated knit tube folded back on itself to form inner and outer panels and having a closed end, an open end, and `a generally tubular configuration between said open and closed ends and characterized by being expandable to enlarge at least the open end thereof,

reinforcing means supported between said open and closed ends and disposed between said inner and outer panels,

said reinforcing means comprising a continuous strip having opposite ends, first and second opposite edges, and said strip extending around said cap body with said first edge adjacent said closed end, said second edge spaced axially from said closed end and said opposite ends meeting with the portions thereof adjacent said second edge and being free to move relative to each other,

and said reinforcing means characterized by being generally expandable in the direction of expansion of said cap body to accommodate said cap body expansion and further being generally rigid in a direction between said open and closed ends to cooperate in providing the shape of said cap and in maintaining that shape. while said cap body remains expandable to accommodate a wearers head.

2. The cap of claim 1 wherein said cap body has an axial and circumferential extension with respect to said tubular cap body, and including a generally circular panel connected to said cap body and forming said closed end, said cap body and said strip being expandable in a circumferential direction and said strip being generally rigid in said axial direction to cooperate in maintaining the tubular conguraton of said cap body.

3. The cap of claim 1 wherein said knit tube has a cuff extension beyond said second strip edge whereby said second strip edge defines a fold line for said cuff,

and wherein said cap includes a visor and -a line of stitching connecting said visor in said cap body adjacent said second strip edge.

4. The cap of claim 3 wherein said reinforcing means comprises buckram means arranged on a bias with respect to the circumferential extension of said cap body.

5. The cap of claim 4 wherein said closed end of said cap body comprises a knit panel having its peripheral edge connected to said cap body and buckram means disposed on the inner side of said panel and extending around the connection between said knit panel and said cap body, said buckram means arranged on a bias with respect to said connection to conform to the configuration of said closed end of said cap body while providing support therefor.

6. The cap of claim Z wherein said reinforcing means comprises buckram means arranged on a bias with respect to the plane of the open end of said cap body.

7. The cap of claim 1 wherein said cap body has a cuff extension beyond said reinforcing means,

a visor backing board,

a visor covering portion of said inner and outer cap body panels folded over and covering said backing board with the edge thereof facing toward said cap body,

and stitiching connecting the edge of said visor covering portion to said cap body to hold said visor backing board in place with said panels covering said board.

8. The cap of claim 7 wherein said cap body includes inwardly extending, peripherally spaced notches in the edge of said inner and outer panels remote from said closed cap end, said notches defining said cuff extension and said portion of said tube covering said backing board,

said notches and visor portions having edges which are sheared and include a generally elastic closure, a line of stitching connecting said elastic closure on said visor covering portion to the cap body and forming the juncture between the cap body arid the visor.

9. The cap of claim 7 wherein said closed end of said cap body comprises a knit panel having its peripheral edge connected to said cap body and buckram means disposed on the inner side of said panel and extending around the connection between said knit panel and said cap body, said buckram means arranged on a bias with respect to said connection to conform to the configuration of said closed end of said cap body while providing support therefor.

10. A cap comprising, in combination,

a cap body comprising an elongated knit tube folded back on itself to form inner and outer panels, said cap body having a closed end, an open end, and a generally tubular extension between said open and closed ends characterized by being expandable to enlarge at least the open end thereof,

reinforcing means comprising continuous buckram means having first and second opposite edges and iirst and second opposite ends, said buckram means extending around said cap body, between said inner and outer panels with said first edge adjacent said closed end, said second edge spaced axially from said closed end, and said opposite ends meeting with the portions thereof adjacent said second edge being free to move relative to each other, said buckram means characterized by being generally movable in the direction of expansion of said cap body to accommodate said cap body expan- 8 t sion and further being generally rigid in a direction between said open and closed ends so that said cap maintains its shape while being expandable to accommodate a wearers head,

said cap body having a cuff extension beyond the second edge of said buckram means,

a visor backing board, y

a portion of said inner and outer cap body panels, folded over and covering said backing board with the edge thereof toward said cap body,

stitching connecting said knit tube portion edge to said cap body to hold said visor backing board in place with said panels covering said board, said stitching connecting said visor into said cap body adjacent said second edge of said buckram means,

and said cap body including inwardly extending, peripherally spaced notches in the edge of said inner and outer panels remote from said closed cap end, said notches defining said cuff extension and said portion of said tube covering said backing board.

11. The cap of claim 10I wherein said buckram means comprises rst and second continuous strips overlaid one on the other.

12. The cap of claim 11 wherein the opposite ends of said irst and second strips are in juxtaposed relation and one set of juxtaposed ends overlapping the other,

means connecting said strips at a point remote from said second edge and adjacent one set of juxtaposed ends and spaced inwardly of the other set, said other set of juxtaposed ends being beveled adjacent said second edge.

References Cited UNITED STATES PATENTS 260,185 6/1882 FOX 2-172 394,469 12/ 1888 Dormer V2-172 473,427 4/ 1892 McLoughlin 2--172 1,267,799 5/ 1918 Perlman 2-195 2,133,619 10/1938 Hutton 2--201 2,143,265 1/1939 Goldstein 2--201 3,337,877 8/1967 Lipkin 2-172 FOREIGN PATENTS 1,199,680 6/1959 France.

MERVIN STEIN, Primary Examiner G. H. KRIZMANICH, Assistant Examiner 

